Drainforce Rail setting new standards in the UK water industry with ‘Pipe Rehabilitation’

Drainforce LtdDrainforce Rail working in collaboration with Alun Griffiths Contractors have installed a first time in the UK water industry UV liner, cured in place with a specification of 23.6mm thickness delivering the project for asset owner Dwr Cymru Welsh Water.

Ultra Violet light (UV) Liner sample indicating scale of thickness.Drainforce Ltd






A surface depression appeared in the road on a busy bus route in central Cardiff, investigations carried out identified a large diameter brick sewer had started to collapse.  A solution was developed to minimise disruption, a quicker completion of the job and reduced excavation in an area what lots of utility services were in the highway.


A solution was developed to minimise disruption and progress quicker solution than full open cut excavation.

The solution to achieve this was to excavate the deformed section of brick sewer, then install a Cured In Place Pipe Lining, the process we followed is summarised below:

Measurements were taken of the pipe size and the liner was designed to withstand the total load imposed on the existing pipe by external groundwater pressure, internal service pressure, ground and traffic loading – thus achieving ‘a new pipe within an old pipe’ structural solution.  The outcome was to manufacture a bespoke liner which was 890mm in diameter and 23.6mm thickness which is the highest specification liner that was fast tracked through the production process in Germany,.  The liner tube material is a combination of non-woven felt and fibreglass, impregnated at the manufacturer’s plant.

The liner was transported to site from Germany in refrigerated vehicle that was used to ensure that curing would not be triggered by premature heat and the liner also had double peroxide applied.  The liner was 45m in length and with a weight of 6.5tonne.

Prior to the lining, the existing pipe was cleaned using a state of art recycler to ensure a close fit could be achieved to the existing sewer, a CCTV survey confirmed the pipe was clean and was also used to mark-up lateral connections.

Lining Installation:

The liner was winched into place through the existing sewer, inflated with air to allow a UV light train to pass through the inflated liner. The light train is controlled by computer and allows UV light to penetrate the polyester resin impregnated liner – the resin having a light sensitive catalyst added. Once the UV light comes in contact with the lining, curing commences – the technique is fast and once the light train has passed a point, the lining at that point is cured consequently the engineer does not have to wait until a number of hours for curing of the full pipeline.

Post Curing:

After the lining was cured, lateral connections were reinstated using a specialist robotic cutter and the pipeline returned to service with a new pipe which has a 70-year guarantee in an old pipe.


Recycler Used to Clean Sewer



Preparation work to Install Liner
Drainforce Ltd

Liner Inflated and Cured in Place

Drainforce Ltd







Drainforce Ltd Liner being winched through existing pipe






Drainforce Ltd  UV Lining Unit





Cured In Place Pipe UV Lining




Drainforce Ltd
Robotic Cutter

Drainforce Ltd  Sewer Before Cleaning & Lining


Drainforce Ltd  Sewer ‘New pipe in and old pipe’


Drainforce Ltd  Sewer Before Cleaning and Lining

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